Metal-clad laminate and metal foil with resin

ABSTRACT

A metal-clad laminate includes an insulating layer including a cured product of a resin composition, and a metal foil disposed on a principal surface of the insulating layer. The resin composition includes a polyphenylene ether copolymer and a thermosetting curing agent, the polyphenylene ether copolymer having an intrinsic viscosity measured in methylene chloride at 25° C. of between 0.03 dl/g and 0.12 dl/g, inclusive. And the polyphenylene ether copolymer has, at a molecular terminal, a group represented by formula (1) or formula (2) at an average number of 1.5 to 3 per one molecule. Further, the metal foil has a first surface that is in contact with the insulating layer, the first surface having a 10-point average roughness (Rz) of 2.0 μm or less. And the metal foil includes a barrier layer disposed at a side of the first surface, the barrier layer containing cobalt.

RELATED APPLICATIONS

This application is a continuation of the PCT International Application No. PCT/JP2016/005133 filed on Dec. 15, 2016, which claims the benefit of foreign priority of Japanese patent application No. 2016-005261 filed on Jan. 14, 2016, the contents all of which are incorporated herein by reference.

BACKGROUND 1. Technical Field

The present disclosure relates to a metal-clad laminate and a metal foil with resin.

2. Description of the Related Art

In recent years, along with an increase in amount of information to be processed, mounting techniques involving, for example, high integration of a semiconductor device to be incorporated, high density of wiring, and multi-layering are rapidly developing in various electronic devices.

Recently, a printed wiring board compatible with high-frequency waves, such as a substrate for a millimeter-wave radar which is for in-vehicle use, is also required. However, there has been a problem that a transmission loss due to a conductor or a dielectric member occurs when a conductor circuit transmits a high frequency signal.

For addressing such a problem, it is known that a resin containing polyphenylene ether or the like, which has a small dielectric constant and a small dielectric dissipation factor, is used as a dielectric member so as to reduce the transmission loss caused by the dielectric member (See, for example, International Publication WO 2014/034103).

On the other hand, a high frequency signal concentrates in a superficial part of a conductor due to the skin effect, meanwhile a surface of a metal foil in a metal-clad laminate is usually roughened so as to improve the adhesive strength with a dielectric. Thus, the signal transmits along the roughness of the roughened metal foil surface.

As for this situation, it is reported a technique that shorten the transmission distance by reducing the surface roughness of the metal foil so as to reduce the transmission loss caused by the conductor (See Unexamined Japanese Patent Publication No. 2004-25835). In Unexamined Japanese Patent Publication No. 2004-25835, it is reported that the surface of the metal foil through which a high frequency signal transmits is subjected by a rustproofing treatment mainly with nickel.

SUMMARY

A metal-clad laminate according to one aspect of the present disclosure includes an insulating layer including a cured product of a resin composition, and a metal foil disposed on a principal surface of the insulating layer. The resin composition includes a polyphenylene ether copolymer and a thermosetting curing agent. The polyphenylene ether copolymer has an intrinsic viscosity measured in methylene chloride at 25° C. of between 0.03 dl/g and 0.12 dl/g, inclusive. Further, the polyphenylene ether copolymer has, at a molecular terminal, a group represented by formula (1) or formula (2) at an average number of 1.5 to 3 per one molecule. The metal foil has a first surface that is in contact with the insulating layer. And, the first surface has a 10-point average roughness (Rz) of 2.0 μm or less. Further, the metal foil includes a barrier layer disposed at a side of the first surface. And the barrier layer contains cobalt.

(in formula (1), R¹ represents a hydrogen atom or an alkyl group having 1 to 10 carbon atoms, and R² represents an alkylene group having 1 to 10 carbon atoms).

(in formula (2), R³ represents a hydrogen atom, or an alkyl group having 1 to 10 carbon atoms).

In the metal-clad laminate, it is preferred that the polyphenylene ether copolymer includes 2,6-dimethylphenol and a bifunctional phenol.

Further, in the metal-clad laminate, it is preferred that the group represented by formula (1) is at least one selected from the group consisting of a p-ethenylbenzyl group and an m-ethenylbenzyl group.

Further, in the metal-clad laminate, it is preferred that the insulating layer includes a glass fabric substrate.

Further, in the metal-clad laminate, it is preferred that the glass fabric substrate has a relative dielectric constant of 5.0 or less, and the insulating layer has a relative dielectric constant of 4.0 or less.

A metal foil with resin according to other aspect of the present disclosure includes an insulating layer including a half-cured product of a resin composition, and a metal foil disposed on a principal surface of the insulating layer. The resin composition includes a polyphenylene ether copolymer and a thermosetting curing agent. The polyphenylene ether copolymer has an intrinsic viscosity measured in methylene chloride at 25° C. of between 0.03 dl/g and 0.12 dl/g, inclusive. Further, the polyphenylene ether copolymer has, at a molecular terminal, a group represented by formula (1) or formula (2) at an average number of 1.5 to 3 per one molecule. The metal foil has a first surface that is in contact with the insulating layer. And, the first surface has a 10-point average roughness (Rz) of 2.0 μm or less. Further, the metal foil includes a barrier layer disposed at a side of the first surface. And the barrier layer contains cobalt.

(in formula (1), R¹ represents a hydrogen atom or an alkyl group having 1 to 10 carbon atoms, and R² represents an alkylene group having 1 to 10 carbon atoms).

(in formula (2), R³ represents a hydrogen atom or an alkyl group having 1 to 10 carbon atoms).

In the metal foil with resin, it is preferred that the polyphenylene ether copolymer includes 2,6-dimethylphenol and a bifunctional phenol.

Further, in the metal foil with resin, it is preferred that the group represented by formula (1) is at least one selected from the group consisting of a p-ethenylbenzyl group and an m-ethenylbenzyl group.

According to the present disclosure, it is possible to provide a metal-clad laminate and a metal foil with resin having excellent heat resistance and transmission characteristics, capable of reducing a transmission loss (transmission loss is less likely to increase) even in transmission of a high frequency signal.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic sectional view illustrating a metal-clad laminate according to an exemplary embodiment; and

FIG. 2 is a schematic sectional view illustrating a metal foil with resin according to an exemplary embodiment.

DETAILED DESCRIPTION OF EMBODIMENT

Nickel that has been conventionally used in a rustproofing treatment of a metal foil is excellent in heat resistance, but has a problem that reduction of the transmission loss is hindered because of high electric resistance of nickel. This tendency is significant particularly when dielectric characteristics of the insulating layer (resin) are decreased or a signal frequency is increased, and an improvement in such a tendency is demanded.

The present disclosure was devised in consideration of such circumstances, and provides a metal-clad laminate and a metal foil with resin capable of reducing a transmission loss even in transmission of a high frequency signal while keeping dielectric characteristics and heat resistance.

As described above, various characteristics are demanded for a metal-clad laminate or a metal foil with resin having an insulating layer formed of a resin composition that are used as electronic materials.

First of all, for realizing high speed communications, it is demanded that the surface of the metal foil to be laminated is relatively smooth (low roughness) and is small in metal resistance so as to achieve excellent transmission characteristics, as well as dielectric characteristics such as a low dielectric constant, a low dielectric dissipation factor or the like. Then, for higher multilayer to improve the wiring density and for environmental friendliness (lead free), characteristics such as high Tg, heat resistance, lower a, and fluidity of a prepreg (a half-cured product of a resin composition) as a substrate material are demanded.

In order to satisfy these characteristics, the metal-clad laminate of the present exemplary embodiment includes an insulating layer including a cured product of a resin composition, and a metal foil on either or both sides of the insulating layer. The resin composition includes a polyphenylene ether copolymer and a thermosetting curing agent. The polyphenylene ether copolymer has an intrinsic viscosity measured in methylene chloride at 25° C. of between 0.03 dl/g and 0.12 dl/g, inclusive. Further, the polyphenylene ether copolymer has, at a molecular terminal, a group represented by formula (1) or formula (2) at an average number of 1.5 to 3 per one molecule. The metal foil has a surface in contact with the insulating layer. The surface in contact with the insulating layer has a 10-point average roughness (Rz) of 2.0 μm or less. Further, The metal foil includes a barrier layer disposed at a side of the surface in contact with the insulating layer. And the barrier layer contains cobalt.

The metal-clad laminate of the present disclosure is capable of reducing the transmission loss by using cobalt having lower electric resistance than nickel in the rustproofing treatment of the metal foil. Here, although cobalt generally tends to be inferior to nickel in heat resistance, a polyphenylene ether-containing resin has also the characteristics of excellent heat resistance in addition to the small dielectric constant and small dielectric dissipation factor. Therefore, it is considered that both reduction in transmission loss and improvement in heat resistance can be realized by combination of use of cobalt in the rustproofing treatment of the metal foil, and use of a polyphenylene ether-containing resin as a dielectric member.

In the following, each configuration of a metal-clad laminate of the present exemplary embodiment is specifically described.

[Metal-Clad Laminate]

FIG. 1 is a schematic sectional view illustrating a metal-clad laminate according to an exemplary embodiment. Metal-clad laminate 1 of the present exemplary embodiment includes insulating layer 2 formed of a cured product of a resin composition, and metal foil 3 disposed on one or both faces of insulating layer 2.

In the present exemplary embodiment, a cured product of a resin composition refers to the resin composition that has proceeded with a curing reaction and does not melt due to cross-linking of the resin even when heated. It should be noted that the half-cured product of a resin composition in later-described metal foil with resin 11 refers to the resin composition in a middle stage of a curing reaction of thermosetting resin, namely the resin composition that once melts and proceeds with a curing reaction when subjected to a rise in temperature.

[Insulating Layer]

Insulating layer 2 of metal-clad laminate 1 of the present exemplary embodiment is formed of a cured product of a resin composition described below. Further, insulating layer 2 may include a later-described glass fabric substrate. Thickness of insulating layer 2 is not particularly limited, but approximately ranges from 20 μm to 800 μm, inclusive.

(Resin Composition)

A resin composition forming insulating layer 2 of the present exemplary embodiment includes a polyphenylene ether copolymer and a thermosetting curing agent. The polyphenylene ether copolymer has an intrinsic viscosity measured in methylene chloride at 25° C. of between 0.03 dl/g and 0.12 dl/g, inclusive. And the polyphenylene ether copolymer has, at a molecular terminal, a group represented by formula (1) or formula (2) at an average number of 1.5 to 3 per one molecule.

By using such a polyphenylene ether resin composition, it is possible to obtain metal-clad laminate 1 having excellent dielectric characteristics and heat resistance. Further, the polyphenylene ether resin composition has excellent reactivity that contributes to the curing reaction and excellent preservation stability. And excellent fluidity of the polyphenylene ether resin composition due to low viscosity also provides an advantage of excellent moldability in the cured product.

The polyphenylene ether copolymer used in the present exemplary embodiment is not particularly limited as long as the polyphenylene ether copolymer has an intrinsic viscosity measured in methylene chloride at 25° C. of between 0.03 dl/g and 0.12 dl/g, inclusive, and has, at a molecular terminal, a group represented by formula (1) or formula (2) at an average number of 1.5 to 3 per one molecule.

(in formula (1), R¹ represents a hydrogen atom or an alkyl group having 1 to 10 carbon atoms, and R² represents an alkylene group having 1 to 10 carbon atoms).

(in formula (2), R³ represents a hydrogen atom or an alkyl group having 1 to 10 carbon atoms).

As described above, in formula (1), R¹ represents a hydrogen atom or an alkyl group having 1 to 10 carbon atoms. The alkyl group having 1 to 10 carbon atoms is not particularly limited as long as the alkyl group is an alkyl group having 1 to 10 carbon atoms, and may be in the form of a straight chain or a branched chain. Specific examples include a methyl group, an ethyl group, a n-propyl group, an isopropyl group, a n-butyl group, an isobutyl group, a s-butyl group, a t-butyl group, a pentyl group, an isopentyl group, a neopentyl group, and a hexyl group. Among these, a hydrogen atom is preferred.

In formula (1), R² represents an alkylene group having 1 to 10 carbon atoms. The alkylene group having 1 to 10 carbon atoms may be any alkylene groups having 1 to 10 carbon atoms including a methylene group, an ethylene group, a propylene group, a butylene group, a pentylene group, a hexylene group, a heptylene group, an octylene group, a nonylene group, and a decylene group. Among these, a methylene group is preferred.

Further, the group represented by formula (1) is preferably, but is not particularly limited to, at least one selected from the group consisting of a p-ethenylbenzyl group and an m-ethenylbenzyl group. It is considered that this makes it possible to obtain the effects described above more certainly.

The group represented by formula (1) may be a single group exemplified in the above, or a combination of two or more groups exemplified in the above.

In formula (2), R³ represents a hydrogen atom or an alkyl group having 1 to 10 carbon atoms. The alkyl group having 1 to 10 carbon atoms is not particularly limited as long as the alkyl group is an alkyl group having 1 to 10 carbon atoms, and may be in the form of a straight chain or a branched chain. Specific examples include a methyl group, an ethyl group, an n-propyl group, an isopropyl group, an n-butyl group, an isobutyl group, an s-butyl group, a t-butyl group, a pentyl group, an isopentyl group, a neopentyl group, and a hexyl group. Among these, a hydrogen atom is preferred.

The intrinsic viscosity of the polyphenylene ether copolymer according to the present exemplary embodiment can range from 0.03 dl/g to 0.12 dl/g, inclusive, and preferably ranges from 0.04 dl/g to 0.11 dl/g, inclusive, more preferably ranges from 0.06 dl/g to 0.095 dl/g, inclusive. If the intrinsic viscosity is too low, the molecular weight tends to be low, and low dielectric property such as low dielectric constant and low dielectric dissipation factor tends to be difficult to be obtained. If the intrinsic viscosity is too high, the viscosity is high, and sufficient fluidity is not obtained. And thus the moldability of the cured product tends to deteriorate. Therefore, when the intrinsic viscosity of the polyphenylene ether copolymer falls within the above range, it is possible to realize excellent heat resistance and moldability of the cured product.

The intrinsic viscosity referred to in the present exemplary embodiment is intrinsic viscosity measured in methylene chloride at 25° C., more specifically, for example, a value obtained by measuring a 0.18 g/45 mL solution in methylene chloride (liquid temperature 25° C.) by a viscometer. Examples of the viscometer include ViscoSystem AVS 500 manufactured by SCHOTT Instruments GmbH.

In the polyphenylene ether copolymer according to the present exemplary embodiment, the average number of groups represented by formula (1) or (2) at a molecular terminal, per one molecule of the polyphenylene ether copolymer (number of terminal functional groups) may be 1.5 to 3, but is preferably 1.7 to 2.7, more preferably 1.8 to 2.5. If the number of terminal functional groups is too small, it is considered that a cross linking point or the like become difficult to be formed, and the cured product having sufficient heat resistance tends to be difficult to be obtained. If the number of terminal functional groups is too large, the reactivity is too high, and problems such as deterioration in preservability of the resin composition, or deterioration in fluidity of the resin composition can occur.

A terminal functional number of the polyphenylene ether copolymer can be a value such as an average value of groups represented by formula (1) or (2) per one molecule of all the polyphenylene ether copolymers existing in 1 mol of polyphenylene ether. The terminal functional number can be determined, for example, by measuring the number of hydroxyl groups remaining in the obtained polyphenylene ether copolymer, and calculating a decrement from the number of hydroxyl groups of the polyphenylene ether copolymer before modification. The decrement from the number of hydroxyl groups of the polyphenylene ether copolymer before modification is a number of terminal functional groups. The number of hydroxyl groups remaining in the polyphenylene ether copolymer after modification can be determined by adding a quaternary ammonium salt that associates with a hydroxyl group (tetraethylammonium hydroxide) to the solution of the polyphenylene ether copolymer, and measuring the UV absorption of the resultant mixed solution.

A weight average molecular weight of the polyphenylene ether copolymer used in the present exemplary embodiment is preferably, but not particularly limited to, 1000 or more. Further, the weight average molecular weight of the polyphenylene ether copolymer used in the present exemplary embodiment ranges preferably from 1000 to 7000, inclusive, more preferably from 1000 to 5000, inclusive, further preferably from 1000 to 3000, inclusive. The weight average molecular weight can be measured by a general molecular weight measuring method, and can be specifically a value measured by using gel permeation chromatography (GPC).

It is assumed that a resin composition having excellent dielectric characteristics possessed by polyphenylene ether and giving high Tg and excellent adhesiveness and heat resistance with good balance in a cured product of the resin composition can be obtained more certainly, when the weight average molecular weight of the polyphenylene ether copolymer falls within such a range.

The polyphenylene ether copolymer according to the present exemplary embodiment has a polyphenylene ether chain in the molecule, and preferably has, for example, a repeating unit represented by formula (3) in the molecule.

In formula (3), m represents 1 to 50. R⁴, R⁵, R⁶ and R⁷ are independent from one another. That is, R⁴, R⁵, R⁶ and R⁷ may be the same group, or different groups. R⁴, R⁵, R⁶ and R⁷ each represent a hydrogen atom, an alkyl group, an alkenyl group, an alkynyl group, a formyl group, an alkylcarbonyl group, an alkenylcarbonyl group, or an alkynylcarbonyl group. Among these, a hydrogen atom and an alkyl group are preferred.

In R⁴, R⁵, R⁶ and R⁷, specific examples of the functional groups are as follows.

The alkyl group is not particularly limited, but is preferably an alkyl groups having 1 to 18 carbon atoms, and more preferably an alkyl group having 1 to 10 carbon atoms, for example. Specific examples include a methyl group, an ethyl group, a propyl group, a hexyl group, and a decyl group.

The alkenyl group is not particularly limited, but is preferably an alkenyl group having 2 to 18 carbon atoms, and more preferably an alkenyl groups having 2 to 10 carbon atoms, for example. Specific examples include a vinyl group, an allyl group, and a 3-butenyl group.

The alkynyl group is not particularly limited, but is preferably an alkynyl group having 2 to 18 carbon atoms, and more preferably an alkynyl groups having 2 to 10 carbon atoms, for example. Specific examples include an ethynyl group, and a prop-2-yn-1-yl group (propargyl group).

While the alkylcarbonyl group is not particularly limited as long as it is a carbonyl group substituted by an alkyl group, for example, an alkylcarbonyl group having 2 to 18 carbon atoms is preferred, and an alkylcarbonyl group having 2 to 10 carbon atoms is more preferred. Specific examples include an acetyl group, a propionyl group, a butyryl group, an isobutyryl group, a pivaloyl group, a hexanoyl group, an octanoyl group, and a cyclohexylcarbonyl group.

While the alkenylcarbonyl group is not particularly limited as long as it is a carbonyl group substituted by an alkenyl group, for example, an alkenylcarbonyl group having 3 to 18 carbon atoms is preferred, and an alkenylcarbonyl group having 3 to 10 carbon atoms is more preferred. Specific examples include an acryloyl group, a methacryloyl group, and a crotonoyl group.

While the alkynylcarbonyl group is not particularly limited as long as it is a carbonyl group substituted by an alkynyl group, for example, an alkynylcarbonyl group having 3 to 18 carbon atoms is preferred, and an alkynylcarbonyl group having 3 to 10 carbon atoms is more preferred. Specific examples include a propioloyl group.

While the weight average molecular weight of the polyphenylene ether copolymer of the present exemplary embodiment is not particularly limited, the weight average molecular weight preferably ranges from 1000 to 5000, inclusive, more preferably ranges from 1000 to 4000, inclusive, further preferably ranges from 1000 to 3000, inclusive. When the polyphenylene ether copolymer has a repeating unit represented by formula (3) in the molecule, m is preferably such a numerical value that the weight average molecular weight of the polyphenylene ether copolymer falls within such a range. Specifically, 1 to 50 is preferred. The weight average molecular weight can be measured by a general molecular weight measuring method, and can be specifically a value measured by using gel permeation chromatography (GPC).

A synthetic method of the polyphenylene ether copolymer used in the present exemplary embodiment is not particularly limited as long as the synthetic method is a method for obtaining a copolymer as described above. Specific examples include a method of reacting a polyphenylene ether in which a hydrogen atom of a terminal phenolic hydroxyl group is substituted with an alkali metal atom such as sodium or potassium, and a compound represented by formula (4).

In formula (4), n represents an integer of 0 to 10, Z represents an arylene group, and R⁸ to R¹⁰ each independently represent a hydrogen atom or an alkyl group. X represents a halogen atom, and specific examples of X include a chlorine atom, a bromine atom, an iodine atom, and a fluorine atom. Among these, a chlorine atom is preferred.

The compound represented by formula (4) is not particularly limited, but is preferably p-chloromethylstyrene or m-chloromethylstyrene, for example.

The compound represented by formula (4) may be a single compound exemplified in the above, or a combination of two or more compounds exemplified in the above.

Polyphenylene ether, which is a raw material, is not particularly limited as long as the polyphenylene ether can finally synthesize the polyphenylene ether copolymer of the present exemplary embodiment. Specific examples include those based on polyphenylene ether, such as a polyphenylene ether copolymer composed of 2,6-dimethylphenol and at least either one of a bifunctional phenol and a trifunctional phenol, or poly(2,6-dimethyl-1,4-phenylene oxide). Specific examples of such a polyphenylene ether include a polyphenylene ether having a structure represented by formula (5).

In formula (5), for example, a total value of s and t preferably ranges from 1 to 30. Also, s preferably ranges from 0 to 20, and t preferably ranges from 0 to 20. That is, it is preferred that s ranges from 0 to 20, t ranges from 0 to 20, and a total of s and t ranges from 1 to 30.

As a synthetic method of a polyphenylene ether copolymer, the method described above can be recited, and specifically, a polyphenylene ether as described above and a compound represented by formula (4) are dissolved in a solvent and stirred. In this manner, the polyphenylene ether and the compound represented by formula (4) react with each other to give a modified polyphenylene ether copolymer used in the present exemplary embodiment.

In this reaction, it is preferred that the reaction is carried out in the presence of an alkali metal hydroxide. It is considered that the reaction proceeds suitably in this manner.

While the alkali metal hydroxide is not particularly limited as long as the alkali metal hydroxide is capable of functioning as a dehalogenation agent, for example, sodium hydroxide can be recited. The alkali metal hydroxide is typically used in a state of an aqueous solution, and specifically, used as a sodium hydroxide aqueous solution.

The reaction conditions such as reaction time, reaction temperature, and the like vary depending on the compound represented by formula (4), and are not particularly limited as long as the conditions allow favorable progression of the reaction as described above. Specifically, the reaction temperature preferably ranges from room temperature to 100° C., more preferably ranges from 30° C. to 100° C. The reaction time preferably ranges from 0.5 hours to 20 hours, more preferably ranges from 0.5 hours to 10 hours.

The solvent used in the reaction is not particularly limited as long as the solvent is capable of dissolving a polyphenylene ether and a compound represented by formula (4), and does not inhibit the reaction between the polyphenylene ether and the compound represented by formula (4). Specific examples include toluene.

It is preferred that the reaction is conducted in the state that a phase transfer catalyst is present in addition to an alkali metal hydroxide. It is preferred that the reaction is conducted in the state that an alkali metal hydroxide and a phase transfer catalyst are present. It is considered that the reaction proceeds suitably in this manner.

Examples of the phase transfer catalyst include, but are not particularly limited, quaternary ammonium salts such as tetra-n-butyl ammonium bromide.

Preferably, the resin composition according to the present exemplary embodiment contains a modified polyphenylene ether copolymer obtained in the manner as described above as a polyphenylene ether copolymer.

As the thermosetting curing agent used in the present exemplary embodiment, those capable of forming cross links and curing by reaction with the polyphenylene ether copolymer are recited. Specific examples include compounds having two or more unsaturated double bonds in the molecule. More specific examples include trialkenylisocyanurate compounds such as triallyl isocyanurate (TRIC), multifunctional methacrylate compounds having two or more methacryl groups in the molecule, multifunctional acrylate compounds having two or more acryl groups in the molecule, and vinyl compounds having two or more vinyl groups in the molecule (multifunctional vinyl compounds) such as polybutadiene. Among these, trialkenylisocyanurate compounds, multifunctional acrylate compounds having two or more acryl groups in the molecule, multifunctional methacrylate compounds, and multifunctional vinyl compounds are preferred. It is considered that cross links are formed more favorably by the curing reaction using such a compound, and it is possible to further improve the heat resistance of the cured product of the resin composition containing the polyphenylene ether copolymer according to the present exemplary embodiment. The thermosetting curing agent may be a single compound exemplified in the above, or a combination of two or more compounds exemplified in the above. As the thermosetting curing agent, a combination of a compound having two or more unsaturated double bonds in the molecule, and a compound having one unsaturated double bond in the molecule may be used. Specific examples of the compound having one unsaturated double bond in the molecule include compounds having one vinyl group in the molecule (monovinyl compounds).

Also, the content proportion of the polyphenylene ether copolymer in the resin composition of the present exemplary embodiment is not particularly limited as long as the content proportion is capable of forming a cured product by reaction with the thermosetting curing agent. For example, the content proportion of the polyphenylene ether copolymer preferably ranges from 30 mass % to 95 mass %, inclusive, more preferably ranges from 40 mass % to 90 mass %, inclusive, further preferably ranges from 50 mass % to 90 mass %, inclusive, in the total amount of the polyphenylene ether copolymer and the thermosetting curing agent. In other words, the content proportion of the thermosetting curing agent preferably ranges from 5 mass % to 70 mass %, inclusive, more preferably ranges from 10 mass % to 60 mass %, inclusive, further preferably ranges from 10 mass % to 50 mass %, inclusive, in the total amount of the polyphenylene ether copolymer and the thermosetting curing agent. It is considered that this content proportion gives more excellent moldability and heat resistance in the cured product while retaining excellent dielectric characteristics of the polyphenylene ether. This is attributable to the fact that cross links are favorably formed by the curing reaction while the content of the polyphenylene ether capable of exerting excellent dielectric characteristics is retained.

The resin composition used in the present exemplary embodiment may be composed of a polyphenylene ether copolymer and a thermosetting curing agent, or may additionally contain other component. Examples of other component include an inorganic filler, a flame retardant, an additive, and a reaction initiator. Even when other component is contained, the total content proportion of the polyphenylene ether copolymer and the thermosetting curing agent, in the entire resin composition is preferably 30 mass % or more, more preferably between 30 mass % and 90 mass %, inclusive, further preferably between 40 mass % and 80 mass %, inclusive.

While the inorganic filler that can be used in the present exemplary embodiment is not particularly limited, an inorganic filler or the like capable of improving the heat resistance or flame resistance of the cured product of the resin composition can be recited. Specific examples include, for example, silica, alumina, talc, ammonium hydroxide, magnesium hydroxide, titanium oxide, mica, aluminum borate, barium sulfate, and calcium carbonate. These inorganic fillers may be used as they are, but are particularly preferably subjected to a surface treatment with a silane coupling agent of a vinyl silane type, a styryl silane type, a methacryl silane type, or an acryl silane type. Metal-clad laminate 1 obtained by using a resin composition in which an inorganic filler having subjected to a surface treatment with such a silane coupling agent has high heat resistance in moisture absorption and tends to have high interlayer peeling strength.

When an inorganic filler is contained, the content proportion of the inorganic filler preferably ranges from 5 mass % to 60 mass %, inclusive, more preferably ranges from 10 mass % to 60 mass %, inclusive, further preferably ranges from 15 mass % to 50 mass %, inclusive, in the entire resin composition.

The resin composition of the present exemplary embodiment may additionally contain a flame retardant for further improving the flame resistance of the cured product of the resin composition. The flame retardant that can be used is not particularly limited, and specific examples of the flame retardant include halogenic flame retardants such as bromic flame retardants, and phosphoric flame retardants. Specific examples of the halogenic flame retardants include bromic flame retardants such as pentabromodiphenyl ether, octabromodiphenyl ether, decabromodiphenyl ether, tetrabromobisphenol A, and hexabromocyclododecane, and chloric flame retardants such as chlorinated paraffin Specific examples of the phosphoric flame retardants include phosphoric acid esters such as condensed phosphoric acid ester or cyclic phosphoric acid ester, phosphazene compounds such as cyclic phosphazene compound, phosphinate flame retardants such as phosphinic acid metal salts, e.g., dialkylphosphinic acid aluminum salt, and melamine flame retardants such as melamine phosphate and melamine polyphosphate. The flame retardant may be a single flame retardant exemplified in the above, or a combination of two or more flame retardants exemplified in the above.

The curing reaction can proceed even when the resin composition of the present exemplary embodiment is composed of a polyphenylene ether copolymer and a thermosetting curing agent. However, since it is sometimes the case that high temperature is difficult to be applied until the curing proceeds depending on the process condition, a reaction initiator may be added. The reaction initiator is not particularly limited as long as the reaction initiator can promote the curing reaction of the polyphenylene ether copolymer and the thermosetting curing agent. Specific examples include oxidizing agents such as α,α′-bis(t-butylperoxy-m-isopropyl)benzene, 2,5-dimethyl-2, 5-di(t-butylperoxy)-3-hexyne, benzoyl peroxide, 3,3′,5,5′-tetramethyl-1,4-diphenoquinone, chloranil, 2,4,6-tri-t-butylphenoxyl, t-butylperoxyisopropyl monocarbonate, and azobisisobutyronitrile. Also, a carboxylic acid metal salt or the like may be used in combination as is necessary. In this manner, it is possible to further promote the curing reaction. Among these, α,α′-bis(t-butylperoxy-m-isopropyl)benzene is preferably used. Since α,α′-bis(t-butylperoxy-m-isopropyl)benzene initiates reaction at a relatively high temperature, it is possible to prevent promotion of the curing reaction at the point of time where curing is not required, such as in prepreg drying, and it is possible to suppress deterioration in preservability of the polyphenylene ether resin composition. Further, since α,α′-bis(t-butylperoxy-m-isopropyl)benzene does not volatile during drying of prepreg or during preservation, and has excellent stability because α,α′-bigt-butylperoxy-m-isopropylkenzene has low volatility. The reaction initiators may be used alone or in combination of two or more.

Examples of additives other than the above include antifoaming agents such as a silicone-based antifoaming agent and an acrylate-based antifoaming agent, a thermostabilizer, an antistatic agent, an ultraviolet absorber, a dye and a pigment, a lubricant, and dispersants such as a wet dispersant.

The resin composition according to the present exemplary embodiment is typically prepared into a varnish form, and is often used as resin varnish in production of metal-clad laminate 1. Such resin varnish is prepared as follows, for example.

First, components that are soluble in an organic solvent, such as a polyphenylene ether copolymer, a thermosetting curing agent, and a compatible type flame retardant as necessary, are introduced and dissolved in an organic solvent. In this procedure, the solution may be heated as necessary. Then, a component that is not soluble in the organic solvent, such as an inorganic filler, an incompatible type flame retardant or the like is added and dispersed to a predetermined dispersion state with use of, for example, a ball mill, a bead mill, a planetary mixer, or a roll mill to prepare a varnish resin composition. The organic solvent used here is not particularly limited as long as the organic solvent dissolves a polyphenylene ether copolymer, a thermosetting curing agent, and the like, and does not inhibit the curing reaction. Specific examples include toluene, cyclohexanone, and propyleneglycol monomethyl ether acetate. The organic solvents may be used alone or in combination of two or more.

(Glass Fabric Substrate)

Preferably, insulating layer 2 of the present exemplary embodiment further contains a glass fabric substrate in addition to the cured product of the resin composition. This offers the advantages of preventing a trouble in processing (cracking), reducing the dimensional change, reducing the linear expansion, and controlling a warp.

The glass fabric substrate is not particularly limited, but is more preferably a glass fabric substrate having low dielectric constant. More specifically, it is preferred to set the relative dielectric constant of the glass fabric substrate so that the relative dielectric constant (at 1 GHz) of insulating layer 2 is 4.0 or less. The relative dielectric constant of insulating layer 2 within the above range can be realized when the relative dielectric constant of the glass fabric substrate is 5.0 or less.

A glass fabric substrate that has a thickness of, for example, about between 0.04 mm and 0.3 mm, inclusive, can be generally used.

As such a glass fabric substrate, a commercially available glass fabric substrate can be used, and for example, “E glass” (relative dielectric constant 6.8) or “NE glass” (relative dielectric constant 4.8) manufactured by Nitto Boseki Co., Ltd. can be preferably used. While a glass fabric substrate having a low dielectric constant is generally known to be very expensive, according to the present exemplary embodiment, excellent dielectric characteristics can be achieved even when a relatively low-priced glass fabric substrate such as “E glass” is used. Therefore, using such a glass fabric substrate having a low dielectric constant is very useful also from the view point of lowering the production cost.

When insulating layer 2 of the present exemplary embodiment contains a glass fabric substrate, a prepreg obtained by impregnating the glass fabric substrate with the resin composition described above may be used. As a method for producing such a prepreg, there is exemplified a method of impregnating the glass fabric substrate with the resin varnish described above (resin composition prepared into a varnish form), followed by drying.

The impregnation of the glass fabric substrate with the resin varnish is performed by, for example, immersion or application. This impregnation can be repeated a plurality of times as necessary. In this procedure, it is also possible to repeat the impregnation with use of a plurality of types of resin varnish that are different in composition and concentration, for adjusting the composition and the amount of resin to finally desired composition and amount of resin.

The glass fabric substrate that has been impregnated with the resin varnish is heated under desired heating conditions of, for example, a temperature ranging from 80° C. to 170° C., and a period ranging from 1 minute to 10 minutes, to give a prepreg in a half-cured state (stage B).

The glass fabric substrate may be used as it is, but is particularly preferably subjected to a surface treatment with a silane coupling agent of a vinyl silane type, a styryl silane type, a methacryl silane type, or an acryl silane type. Metal-clad laminate 1 containing a glass fabric substrate having subjected to a surface treatment with such a silane coupling agent has high heat resistance in moisture absorption and tends to have high interlayer peeling strength.

[Metal Foil]

Metal-clad laminate 1 of the present exemplary embodiment includes metal foil 3 on either or both sides of insulating layer 2, and metal foil 3 has a barrier layer composed of cobalt (Co) at a side of a surface in contact at least with insulating layer 2, and the surface in contact with insulating layer 2 has a 10-point average roughness (Rz) of 2.0 μm or less.

When a conductor circuit transmits a high frequency signal, the signal concentrates in a superficial part of the conductor due to the skin effect. Since metal foil 3 used in the present exemplary embodiment has a 10-point average roughness (Rz) of the surface in contact with insulating layer 2, which is a dielectric member, of as low as 2.0 μm or less, it is considered that the transmission distance is shortened, and the transmission loss can be reduced. While the lower limit of the 10-point average roughness (Rz) of the surface of metal foil 3 is not particularly limited as long as the 10-point average roughness (Rz) is 2.0 μm or less, it is preferred that the 10-point average roughness (Rz) is preferably 0.5 μm or more from the view point of obtaining a certain degree of adhesiveness with insulating layer 2. In the present exemplary embodiment, the 10-point average roughness (Rz) means Rz JIS defined in JIS B 0601-2001.

Metal foil 3 used in the present exemplary embodiment is not particularly limited, and for example, a copper foil, a nickel foil, an aluminum foil or the like can be used, however, from the view point of workability, conductivity or the like, a copper foil is preferably used. Thickness of metal foil 3 is not particularly limited, but is, preferably about between 12 μm and 70 μm, inclusive.

On at least a surface of metal foil 3 of the present exemplary embodiment where metal foil 3 is in contact with insulating layer 2, a barrier layer composed of cobalt is formed. It is considered that cobalt is capable of further reducing the transmission loss because cobalt has relatively low electric resistance. Conventionally, cobalt tends to be inferior to nickel or the like in heat resistance, however, in the present exemplary embodiment, it is possible to achieve both the heat resistance and the reduction in transmission loss by using the resin composition containing the polyphenylene ether copolymer as insulating layer 2.

The barrier layer in metal foil 3 of the present exemplary embodiment may contain tin, zinc, nickel or the like besides cobalt unless the effect of the present disclosure is impaired. It is preferred that, tin and nickel, in particular are not contained as much as possible, because tin and nickel have high electric resistance as described above. Also for the purpose of preventing surface oxidization of a copper foil, a rustproofing treatment such as a chromate treatment may be conducted.

Metal foil 3 may be used as it is, but is particularly preferably subjected to a surface treatment with a silane coupling agent of a vinyl silane type, a styryl silane type, a methacryl silane type, or an acryl silane type. Metal-clad laminate 1 containing metal foil 3 having subjected to a surface treatment with such a silane coupling agent has high heat resistance in moisture absorption and tends to have high interlayer peeling strength.

The barrier layer can be formed by a plating treatment. Specifically, for example, a thin film of cobalt or an alloy of cobalt can be formed on metal foil 3 by sputtering, electroplating or electroless plating.

As metal foil 3 of the present exemplary embodiment, commercially available products can be used, and preferred examples include “T9FZ-SV” (Rz: 1.6 μm) and “T9DA-SV” (Rz: 1.0 μm) manufactured by FUKUDA METAL FOIL & POWDER CO.; LTD.

[Method for Producing Metal-Clad Laminate]

Metal-clad laminate 1 of the present exemplary embodiment can be manufactured as a laminate whose one or both surfaces are clad with a metal foil, for example, by stacking one or a plurality of prepregs containing the resin composition as described above, and further stacking metal foil 3 as described above on either or both sides above or below the prepreg stack, followed by heat pressure molding of the resultant stack for lamination and integration.

The heating and pressurizing conditions can be appropriately set depending on the thickness of the laminate to be produced, the kind of the resin composition, and the like, and for example, the temperature can range from 170° C. to 220° C., the pressure can range from 1.5 MPa to 5.0 MPa, and the period can range from 60 minutes to 150 minutes.

[Metal Foil with Resin]

FIG. 2 is a schematic sectional view illustrating a metal foil with resin according to an exemplary embodiment. Metal foil with resin 11 of the present exemplary embodiment includes insulating layer 12 formed of a half-cured product of the resin composition described above, and metal foil 3 disposed on one side of insulating layer 12.

As the resin composition used in insulating layer 12 and metal foil 3, those described in the metal-clad laminate can be used.

One exemplary method for producing metal foil with resin 11 includes applying the resin varnish obtained in the above on the surface of metal foil 3 where the barrier layer is formed, and then drying the resin varnish to half-cure the resin composition.

Since insulating layer 12 of metal foil with resin 11 typically does not contain a glass fabric substrate, application of the resin varnish to metal foil 3 is conducted by coating or the like, and the application can be repeated several times as necessary. In this procedure, it is also possible to repeat the application with use of a plurality of types of resin varnish that are different in composition and concentration, for adjusting the composition and resin thickness to a finally desired composition (content ratio) and resin amount.

After application of the resin varnish, by removing the solvent by heating under desired heating conditions of, for example, 80° C. to 180° C. and 1 minute to 10 minutes, metal foil with resin 11 having the resin composition in the half-cured state (stage B) as insulating layer 12 is obtained.

Metal foil with resin 11 of the present exemplary embodiment also has the same effect and advantages as metal-clad laminate 1 described above.

Metal-clad laminate 1 and metal foil with resin 11 of the present exemplary embodiment can be used as a wiring board that is provided with a conductor pattern as a circuit on the surface, by forming a circuit by subjecting metal foil 3 on the surface to an etching process or the like. A wiring board obtained by using metal-clad laminate 1 and metal foil with resin 11 of the present exemplary embodiment is excellent in heat resistance, dielectric characteristics, and transmission characteristics, and has an advantage that the wiring board is easy to mount and has no variation in quality even when the wiring board is formed into a package to which a semiconductor chip is joined.

The present specification discloses various aspects of techniques as described above, from among which main techniques are summarized as follows.

A metal-clad laminate according to one aspect of the present disclosure includes an insulating layer containing a cured product of a resin composition, and a metal foil disposed on a principal surface of the insulating layer. The resin composition includes a polyphenylene ether copolymer and a thermosetting curing agent. The polyphenylene ether copolymer has an intrinsic viscosity measured in methylene chloride at 25° C. of between 0.03 dl/g and 0.12 dl/g, inclusive. And, the polyphenylene ether copolymer has, at a molecular terminal, a group represented by formula (1) or formula (2) at an average number of 1.5 to 3 per one molecule. The metal foil has a first surface that is in contact with the insulating layer, and the first surface has a 10-point average roughness (Rz) of 2.0 μm or less. Further, the metal foil includes a barrier layer disposed at a side of the first surface. And the barrier layer contains cobalt.

With such a configuration, it is possible to provide an electronic material having excellent dielectric characteristics and heat resistance, and excellent transmission characteristics.

In the metal-clad laminate, it is preferred that the polyphenylene ether copolymer includes 2,6-dimethylphenol and a bifunctional phenol. This makes it possible to obtain the effects described above more certainly.

Further, in the metal-clad laminate, it is preferred that the group represented by formula (1) is at least one selected from the group consisting of a p-ethenylbenzyl group and an m-ethenylbenzyl group. This makes it possible to obtain the effects described above more certainly.

Further, in the metal-clad laminate, it is preferred that the insulating layer includes a glass fabric substrate. This makes it possible to obtain more excellent dielectric characteristics more certainly.

Further, in the metal-clad laminate, it is preferred that the glass fabric substrate has a relative dielectric constant of 5.0 or less, and the insulating layer has a relative dielectric constant of 4.0 or less. This makes it possible to obtain more excellent dielectric characteristics more certainly.

A metal foil with resin according to other aspect of the present disclosure includes an insulating layer containing a half-cured product of a resin composition, and a metal foil disposed on a principal surface of the insulating layer. The resin composition includes a polyphenylene ether copolymer and a thermosetting curing agent. The polyphenylene ether copolymer has an intrinsic viscosity measured in methylene chloride at 25° C. of between 0.03 dl/g and 0.12 dl/g, inclusive. And, the polyphenylene ether copolymer has, at a molecular terminal, a group represented by formula (1) or formula (2) at an average number of 1.5 to 3 per one molecule. The metal foil has a first surface that is in contact with the insulating layer. And the first surface has a 10-point average roughness (Rz) of 2.0 μm or less. Further, the metal foil includes a barrier layer disposed at a side of the first surface. And the barrier layer contains cobalt.

With such a configuration, it is possible to provide an electronic material having excellent dielectric characteristics and heat resistance, and excellent transmission characteristics.

In the metal foil with resin, it is preferred that the polyphenylene ether copolymer includes 2,6-dimethylphenol and a bifunctional phenol. This makes it possible to obtain the effects described above more certainly.

Further, in the metal foil with resin, it is preferred that the group represented by formula (1) is at least one selected from the group consisting of a p-ethenylbenzyl group and an m-ethenylbenzyl group. This makes it possible to obtain the effects described above more certainly.

Hereinafter, the present disclosure will be described more specifically by way of examples. A scope of the present disclosure, however, is not limited to these examples.

EXAMPLES

First, a modified polyphenylene ether copolymer was synthesized. An average number of phenolic hydroxyl groups at a molecular terminal per one molecule of polyphenylene ether is indicated as a number of terminal hydroxyl groups.

[Synthesis of Modified Polyphenylene Ether 1 (Modified PPE1)]

A polyphenylene ether and chloromethylstyrene were reacted to obtain modified polyphenylene ether 1 (modified PPE1).

Specifically, in a 1 L three-neck flask equipped with a temperature controller, a stirrer, a cooling installation, and a dropping funnel, 200 g of polyphenylene ether (polyphenylene ether having a structure shown in formula (5), SA90 manufactured by SABIC Innovative Plastics, intrinsic viscosity (IV) 0.083 dl/g, number of terminal hydroxyl groups 1.9, weight average molecular weight Mw 2000), 30 g of a mixture of p-chloromethylstyrene and m-chloromethylstyrene in a mass ratio of 50:50 (chloromethylstyrene:CMS, manufactured by TOKYO CHEMICAL INDUSTRY CO., LTD.), 1.227 g of tetra-n-butylammonium bromide as a phase transfer catalyst, and 400 g of toluene were introduced and stirred. Then the resultant mixture was stirred until polyphenylene ether, chloromethylstyrene, and tetra-n-butylammonium bromide were dissolved in toluene. In the procedure, the mixture was gradually heated so that the liquid temperature reached finally to 75° C. Then to the resultant solution, a sodium hydroxide aqueous solution (20 g sodium hydroxide/20 g water) as an alkali metal hydroxide was dropped over 20 minutes. Then the solution was further stirred for 4 hours at 75° C. Then after neutralizing the contents of the flask with 10 mass % hydrochloric acid, a large amount of ethanol was introduced. This caused generation of a precipitation in the liquid in the flask. That is, a product contained in the reaction liquid in the flask was reprecipitated. Then the precipitate was taken out by filtration, and washed three times with a mixture of methanol and water in a mass ratio of 80:20, and then dried in vacuo at 80° C. for 3 hours.

The obtained solid was analyzed by ¹H-NMR (400 MHz, CDCl₃, TMS). In the measurement result of NMR, a peak derived from ethenylbenzyl was observed in the range of 5 ppm to 7 ppm. This confirmed that the obtained solid is a modified polyphenylene ether having a group represented by formula (1) at a molecular terminal. Specifically, it was confirmed that the obtained solid is an ethenylbenzylated polyphenylene ether.

The terminal functional number of the modified polyphenylene ether was measured in the following manner.

First, a modified polyphenylene ether was weighed accurately. The weight at that time is referred to as X (mg). Then the weighed modified polyphenylene ether was dissolved in 25 mL of methylene chloride, and to the resultant solution, 100 μL of a 10 mass % solution of tetraethylammonium hydroxide (TEAH) in ethanol (TEAH:ethanol (volume ratio)=15:85) was added, and then absorbance (Abs) at 318 nm was measured by using an UV spectrophotometer (UV-1600, manufactured by Shimadzu Corporation). Then, from the measurement result, a number of terminal hydroxyl groups of the modified polyphenylene ether was calculated by using the following formula.

Residual OH amount (μmol/g)=[(25×Abs)/(ε×OPL×X)]×10⁶

Here, ε represents an absorption coefficient, and is 4700 L/mol cm. Further, OPL is an optical length of cell, and is 1 cm.

Since the calculated residual OH amount (number of terminal hydroxyl groups) of the modified polyphenylene ether is substantially zero, it was found that the hydroxyl groups of the polyphenylene ether before modification were substantially modified. This revealed that the decrement from the number of terminal hydroxyl groups of the polyphenylene ether before modification is the number of terminal hydroxyl groups of the polyphenylene ether before modification. In other words, it was found that the number of terminal hydroxyl groups of the polyphenylene ether before modification is the number of terminal functional groups of the modified polyphenylene ether. That is, the terminal functional number was 1.9.

Intrinsic viscosity (IV) of the modified polyphenylene ether was measured in methylene chloride at 25° C. Specifically, intrinsic viscosity (IV) of the modified polyphenylene ether was measured in a 0.18 g/45 mL solution of modified polyphenylene ether in methylene chloride (liquid temperature 25° C.) with a viscometer (AVS500 Visco System manufactured by Schott). As a result, intrinsic viscosity (IV) of the modified polyphenylene ether was 0.086 dl/g.

Also, a molecular weight distribution of the modified polyphenylene ether was measure by using GPC. Then, from the obtained molecular weight distribution, a weight average molecular weight (Mw) and a content of a high molecular weight component having a molecular weight of 13000 or more were calculated. Specifically, the content of a high molecular weight component was calculated from the ratio of the peak area based on the curve showing the molecular weight distribution obtained by GPC. As a result, Mw was 2300. The content of a high molecular weight component was 0.1 mass %.

[Synthesis of Modified Polyphenylene Ether 2 (Modified PPE2)]

Modified PPE2 was synthesized in the same method as in the synthesis of modified PPE1 described above except that a later-described polyphenylene ether was used as the polyphenylene ether, and a later-described condition was employed.

The polyphenylene ether used herein was the one obtained by distributing and rearranging the polyphenylene ether having a structure shown by formula (5) (SA90 manufactured by SABIC Innovative Plastics, intrinsic viscosity (IV) 0.083 dl/g, number of terminal hydroxyl groups 1.9, weight average molecular weight Mw 2000). Specifically, distribution and rearrangement were conducted in the following manner.

First, 200 g of the polyphenylene ether (SA90), 40 g of bisphenol A as a phenol species, and 40 g of benzoyl peroxide (NYPER BW, manufactured by NOF CORPORATION) as an initiator were mixed, and to the resultant mixture 400 g of toluene which is a solvent was added and mixed at 90° C. for 1 hour. In this manner, a distributed and rearranged polyphenylene ether was obtained.

Next, reaction between polyphenylene ether and chloromethylstyrene was conducted in the same method as in synthesis of modified PPE1 except that 200 g of the aforementioned distributed and rearranged polyphenylene ether, 65 g of CMS, and 1.92 g of a phase transfer catalyst (tetra-n-butylammonium bromide) were used, and a sodium hydroxide aqueous solution (40 g sodium hydroxide/40 g water) was used in place of a sodium hydroxide aqueous solution (20 g sodium hydroxide/20 g water).

Then the solid obtained in the manner as described above was analyzed by ¹H-NMR (400 MHz, CDCl₃, TMS). In the measurement result of NMR, a peak derived from ethenylbenzyl was observed in the range of 5 to 7 ppm. This confirmed that the obtained solid is a modified polyphenylene ether having a group represented by formula (1) at a molecular terminal. Specifically, it was confirmed that the obtained solid is an ethenylbenzylated polyphenylene ether.

The terminal functional number of the modified polyphenylene ether was measured in the same method as described above. As a result, the terminal functional number was 2.

Intrinsic viscosity (IV) in methylene chloride at 25° C. of the modified polyphenylene ether was measured in the same method as described above. As a result, intrinsic viscosity (IV) of the modified polyphenylene ether was 0.065 dl/g.

Mw and a content of high molecular weight components of the modified polyphenylene ether were measured in the same method as described above. As a result, Mw was 1000. The content of high molecular weight components was 0.1 mass %.

[Synthesis of Modified Polyphenylene Ether 3 (Modified PPE3)]

Modified PPE3 was synthesized in the same method as in the synthesis of modified PPE1 described above except that a later-described polyphenylene ether was used as the polyphenylene ether, and a later-described condition was employed.

The polyphenylene ether used herein was a polyphenylene ether having a structure shown by formula (5) (SA120 manufactured by SABIC Innovative Plastics, intrinsic viscosity (IV) 0.125 dl/g, number of terminal hydroxyl groups 1, weight average molecular weight Mw 3100).

Next, reaction between polyphenylene ether and chloromethylstyrene was conducted in the same method as in synthesis of modified PPE1 except that 200 g of the aforementioned polyphenylene ether (SA120), 15 g of CMS, and 0.92 g of a phase transfer catalyst (tetra-n-butylammonium bromide) were used, and a sodium hydroxide aqueous solution (10 g sodium hydroxide/10 g water) was used in place of a sodium hydroxide aqueous solution (20 g sodium hydroxide/20 g water).

Then, the obtained solid was analyzed by ¹H-NMR (400 MHz, CDCl₃, TMS). In the measurement result of NMR, a peak derived from ethenylbenzyl was observed in the range of 5 to 7 ppm. This confirmed that the obtained solid is a modified polyphenylene ether having a group represented by formula (1) at a molecular terminal. Specifically, it was confirmed that the obtained solid is an ethenylbenzylated polyphenylene ether.

The terminal functional number of the modified polyphenylene ether was measured in the same method as described above. As a result, the terminal functional number was 0.9.

Intrinsic viscosity (IV) in methylene chloride at 25° C. of the modified polyphenylene ether was measured in the same method as described above. As a result, intrinsic viscosity (IV) of the modified polyphenylene ether was 0.125 dl/g.

Mw and a content of high molecular weight components of the modified polyphenylene ether were measured in the same method as described above. As a result, Mw was 3300. The content of high molecular weight components was 0.1 mass %.

Examples 1 to 6 and Comparative Examples 1 to 3

In the present example, components used in preparing a metal foil with resin (Example 6) and a metal-clad laminate (other examples and comparative examples) are described.

(Polyphenylene Ether)

Modified PPE1 to PPE3: Modified polyphenylene ethers obtained by the synthetic method as described above

SA9000: SA9000 manufactured by SABIC Innovative Plastics (modified polyphenylene ether obtained by modifying a terminal hydroxyl group of a polyphenylene ether of formula (5) with a methacryl group)

(Thermosetting Curing Agent)

TAIC: Triallyl isocyanurate (manufactured by Nihon Kasei Co., Ltd.)

(Reaction Initiator)

Initiator: 1,3-bis(butylperoxyisopropyl) benzene (PERBUTYL P, manufactured by NOF CORPORATION)

(Inorganic Filler)

Spherical silica: “SC2300-SVJ”, manufactured by Admatechs.

(Metal Foil)

Copper foil 1: Copper foil having a cobalt barrier layer “T9FZ-SV” (manufactured by FUKUDA METAL FOIL & POWDER CO.; LTD., Rz: 1.6, Thickness 18 μm)

Copper foil 2: Copper foil having a Ni (nickel) barrier layer “T4X-SV” (manufactured by FUKUDA METAL FOIL & POWDER CO.; LTD., Rz: 1.1, Thickness 18 μm)

Copper foil 3: Copper foil having a cobalt barrier layer “T9DA-SV” (manufactured by FUKUDA METAL FOIL & POWDER CO.; LTD., Rz: 1.0, Thickness 18 μm)

Copper foil 4: Copper foil having a cobalt barrier layer “T9FZ-HS” (manufactured by FUKUDA METAL FOIL & POWDER CO.; LTD., Rz: 6.0, Thickness 18 μm)

(Glass Fabric Substrate)

Glass fabric substrate 1: #2116 type, WEA116E, “E glass” (manufactured by Nitto Boseki Co., Ltd., relative dielectric constant 6.8)

Glass fabric substrate 2: #2116 type, NEA116, “NE glass” (manufactured by Nitto Boseki Co., Ltd., relative dielectric constant 4.8)

[Method for Preparing Resin Varnish]

First, components other than the initiator were added in the mixing ratio shown in Table 1 (mixing ratio in Table is indicated by part by mass) into toluene and mixed so that the solid concentration was 50 mass %. The resultant mixture was heated to 80° C. and stirred for 30 minutes while the temperature was kept at 80° C. Thereafter, the stirred mixture was cooled to 40° C., and then 1,3-bis(butylperoxyisopropyl) benzene (PERBUTYL P, manufactured by NOF CORPORATION) which is an initiator was added in the mixing ratio shown in Table 1 to give a resin composition in a varnish form (resin varnish) of each of examples and comparative examples.

Examples 1 to 5 and Comparative Examples 1 to 3

Next, a glass fabric substrate shown in Table 1 was impregnated with each obtained resin varnish, and then dried by heating at 130° C. for about 3 minutes to 8 minutes to give a prepreg. In the procedure, the content of resin components such as polyphenylene ether, a thermosetting curing agent, and the like (resin content) was adjusted to be about 50 mass %.

Then 6 sheets of each obtained prepreg were stacked, and a copper foil shown in Table 1 was overlaid on both sides, and then the resultant stack was heated and pressurized at a temperature of 200° C. for 2 hours, under a pressure of 3 MPa, to give a metal-clad laminate for evaluation having a thickness of 0.8 mm.

Example 6

Using the resin varnish, a copper foil with resin (RCC) was prepared. The resin varnish was applied on a copper foil so that cured resin varnish gave a thicknesses of 130 μm, and dried by heating at 130° C. for 3 minutes until the resin varnish became a half-cured state, to give RCC.

<Evaluation Test>

The laminate for evaluation and RCC prepared as described above were evaluated by methods described below.

[Dielectric Characteristics (Relative Dielectric Constant (Dk) and Dielectric Dissipation Factor (Df))]

A relative dielectric constant and a dielectric dissipation factor of each substrate for evaluation (copper-clad laminate and RCC obtained in the above) at 10 GHz were measured by the cavity resonator perturbation method. Specifically, a relative dielectric constant and a dielectric dissipation factor of the substrate for evaluation were measured at 10 GHz with use of a network analyzer (N5230A manufactured by Agilent Technologies).

[Transmission Characteristics (15 GHz)]

First, a substrate for evaluating transmission characteristics was prepared in the following manner.

Regarding Examples 1 to 5 and Comparative Examples 1 to 3, a glass fabric substrate (#1078 type, WEA116E, “E glass” (manufactured by Nitto Boseki Co., Ltd., relative dielectric constant 6.8) for Examples 1 to 3, 5 and Comparative Examples 1 to 3; #1078 type, NEA116, “NE glass” (manufactured by Nitto Boseki Co., Ltd., relative dielectric constant 4.8) for Example 4) was impregnated with each resin varnish obtained in Examples 1 to 5 and Comparative Examples 1 to 3, and then dried by heating at 130° C. for about 3 minutes to 8 minutes to give a prepreg. In the procedure, the content of resin components such as the polyphenylene ether and the thermosetting curing agent (resin content) was adjusted to be about 60 mass %.

Then 2 sheets of each obtained prepreg were stacked, and a copper foil shown in Table 1 was overlaid on both sides, and then the resultant stack was heated and pressurized at a temperature of 200° C. for 2 hours, under a pressure of 3 MPa, to obtain a metal-clad laminate for evaluation having a thickness of 150 μm.

Next, either face of the double face laminate was processed at a line width ranging from 100 μm to 200 μm, and then two sheets of prepreg were secondarily stacked to sandwich the processed face, to prepare a triple layer laminate. The line width was adjusted so that the characteristic impedance of the circuit after finishing was 50Ω.

Regarding Example 6, the resin varnish obtained in Example 6 was applied on a copper foil so that cured resin varnish gave a thicknesses of 150 μm, and dried by heating at 130° C. for 3 minutes until the resin varnish became a half-cured state, to give RCC.

Then the metal foil was disposed on the resin surface of the obtained RCC and molded, and a copper foil shown in Table 1 was overlaid on both sides, and then the resultant stack was heated and pressurized at a temperature of 200° C. for 2 hours, under a pressure of 3 MPa, to give a metal-clad laminate for evaluation having a thickness of 0.15 mm.

Next, either face of the double face laminate was processed at a line width ranging from 100 μm to 200 μm, and then one sheet of RCC was disposed to sandwich the processed face, to prepare a triple layer laminate. The line width was adjusted so that the characteristic impedance of the circuit after finishing was 50Ω.

For each obtained triple layer laminate, transmission loss was evaluated as transmission characteristics by using a network analyzer (N5230A, manufactured by Keysight Technologies). The evaluation frequency was 15 GHz.

[Glass Transition Temperature (Tg)]

The Tg of the copper-clad laminate obtained in the above was measured using a dynamic mechanical spectrometer “DMS100” manufactured by Seiko Instruments Inc. In the measurement, dynamic mechanical analysis (DMA) was carried out at a frequency of 10 Hz with a tensile module, and the Tg was defined as a temperature at which tan δ showed a local maximal value when the temperature was raised from room temperature up to 320° C. under a condition with a temperature raising speed of 5° C./minute.

[280° C. Oven Heat Resistance Test]

A test piece prepared according to JIS C6481 using the obtained copper foil-clad laminate was treated for 1 hour in a thermostatic bath equipped with an air circulator set at 280° C., and the sample in which all the five test pieces were not abnormal was determined as “OK”, and the sample in which “blistering” or “peeling” occurred in one or more of the five test pieces was determined as “NG”.

These test results are shown in Table 1.

TABLE 1 Name of Example 1 Example 2 Example 3 Name of material manufacturer Composition Composition Composition (PPE PPE-1 (IV = 0.08 dl/g, Self-made 70 copolymer) functional group 1.9) PPE-2 (IV = 0.06 dl/g, Self-made 70 functional group 1.9) PPE-3 (IV = 0.13 dl/g, Self-made functional group 1.0) SA9000 (methacryl terminal) SABIC 70 (Cross-linker) TAIC Nihon Kasei 30 30 30 (Reaction PBP NOF 1 1 1 initiator) (Filler) SC2300-SVJ Admatechs 50 50 50 (Copper foil) T9FZ-SV Co treatment Rz 1.6 FUKUDA METAL ◯ ◯ ◯ T4X-SV Ni treatment Rz 1.1 FUKUDA METAL T9DA-SV Co treatment Rz 1.0 FUKUDA METAL T9FZ-HS Co treatment Rz 6.0 FUKUDA METAL (Glass fabric E glass Nitto Boseki ◯ ◯ ◯ substrate) NE glass Nitto Boseki Example 1 Example 2 Example 3 Items Performance Performance Performance Relative dielectric constant 10 GHz 3.6 3.6 3.6 Dielectric dissipation factor 10 GHz 0.005 0.005 0.005 Transmission characteristics 15 GHz dB/m −27 −27 −27.5 Tg ° C. 230 250 220 Oven heat resistance 280° C. OK OK OK Name of Example 4 Example 5 Example 6 Name of material manufacturer Composition Composition Composition (PPE PPE-1 (IV = 0.08 dl/g, Self-made 70 70 70 copolymer) functional group 1.9) PPE-2 (IV = 0.06 dl/g, Self-made functional group 1.9) PPE-3 (IV = 0.13 dl/g, Self-made functional group 1.0) SA9000 (methacryl terminal) SABIC (Cross-linker) LAIC Nihon Kasei 30 30 30 (Reaction PBP NOF 1 1 1 initiator) (Filler) SC2300-SVJ Admatechs 50 50 50 (Copper foil) T9FZ-SV Co treatment Rz 1.6 FUKUDA METAL ◯ ◯ T4X-SV Ni treatment Rz 1.1 FUKUDA METAL T9DA-SV Co treatment Rz 1.0 FUKUDA METAL ◯ T9FZ-HS Co treatment Rz 6.0 FUKUDA METAL (Glass fabric E glass Nitto Boseki ◯ None substrate) NE glass Nitto Boseki ◯ None Example 4 Example 5 Example 6 Items Performance Performance Performance Relative dielectric constant 10 GHz 3.2 3.6 2.8 Dielectric dissipation factor 10 GHz 0.003 0.005 0.003 Transmission characteristics 15 GHz dB/m −23 −26 −22 Tg ° C. 230 230 230 Oven heat resistance 280° C. OK OK OK Comparative Comparative Comparative Name of Example 1 Example 2 Example 3 Name of material manufacturer Composition Composition Composition (PPE PPE-1 (IV = 0.08 dl/g, Self-made 70 70 copolymer) functional group 1.9) PPE-2 (IV = 0.06 dl/g, Self-made functional group 1.9) PPE-3 (IV = 0.13 dl/g, Self-made 70 functional group 1.0) SA9000 (methacryl terminal) SABIC (Cross-linker) TAIC Nihon Kasei 30 30 30 (Reaction PBP NOF 1 1 1 initiator) (Filler) SC2300-SVJ Admatechs 50 50 50 (Copper foil) T9FZ-SV Co treatment Rz 1.6 FUKUDA METAL T4X-SV Ni treatment Rz 1.1 FUKUDA METAL ◯ ◯ T9DA-SV Co treatment Rz 1.0 FUKUDA METAL T9FZ-HS Co treatment Rz 6.0 FUKUDA METAL ◯ (Glass fabric E glass Nitto Boseki ◯ ◯ ◯ substrate) NE glass Nitto Boseki Comparative Comparative Comparative Example 1 Example 2 Example 3 Items Performance Performance Performance Relative dielectric constant 10 GHz 3.6 3.6 3.6 Dielectric dissipation factor 10 GHz 0.005 0.005 0.005 Transmission characteristics 15 GHz dB/m −29 −34 −27 Tg ° C. 230 230 215 Oven heat resistance 280° C. OK OK NG

As is apparent from the result of Table 1, it was confirmed that the metal-clad laminate and the metal foil with resin of the present disclosure have excellent dielectric characteristics and heat resistance, and also have excellent transmission characteristics. In particular, Example 4 using a glass fabric substrate having a low dielectric constant showed very excellent dielectric characteristics and transmission characteristics.

In contrast to this, Comparative Example 1 using a metal foil having a barrier layer by the Ni treatment, and Comparative Example 2 in which the surface roughness of the metal foil is large were inferior in transmission characteristics. Comparative Example 3 in which the viscosity and the number of functional groups of the polyphenylene ether copolymer fail to satisfy the ranges of the present disclosure had lower Tg and was inferior in heat resistance.

The present disclosure is applicable to a metal-clad laminate and a metal foil with resin. 

What is claimed is:
 1. A metal-clad laminate comprising: an insulating layer including a cured product of a resin composition, and a metal foil disposed on a principal surface of the insulating layer, wherein: the resin composition includes a polyphenylene ether copolymer and a thermosetting curing agent, the polyphenylene ether copolymer having an intrinsic viscosity measured in methylene chloride at 25° C. of between 0.03 dl/g and 0.12 dl/g, inclusive, the polyphenylene ether copolymer having, at a molecular terminal, a group represented by formula (1) or formula (2) at an average number of 1.5 to 3 per one molecule, and the metal foil has a first surface that is in contact with the insulating layer, the first surface having a 10-point average roughness (Rz) of 2.0 μm or less, and includes a barrier layer disposed at a side of the first surface, the barrier layer containing cobalt,

in formula (1), R¹ represents a hydrogen atom or an alkyl group having 1 to 10 carbon atoms, and R² represents an alkylene group having 1 to 10 carbon atoms,

in formula (2), R³ represents a hydrogen atom or an alkyl group having 1 to 10 carbon atoms.
 2. The metal-clad laminate according to claim 1, wherein the polyphenylene ether copolymer includes 2,6-dimethylphenol and a bifunctional phenol.
 3. The metal-clad laminate according to claim 1, wherein the group represented by formula (1) is at least one selected from the group consisting of a p-ethenylbenzyl group and an m-ethenylbenzyl group.
 4. The metal-clad laminate according to claim 1, wherein the insulating layer includes a glass fabric substrate.
 5. The metal-clad laminate according to claim 4, wherein: the glass fabric substrate has a relative dielectric constant of 5.0 or less, and the insulating layer has a relative dielectric constant of 4.0 or less.
 6. A metal foil with resin comprising: an insulating layer including a half-cured product of a resin composition, and a metal foil disposed on a principal surface of the insulating layer, wherein: the resin composition includes a polyphenylene ether copolymer and a thermosetting curing agent, the polyphenylene ether copolymer having an intrinsic viscosity measured in methylene chloride at 25° C. of between 0.03 dl/g and 0.12 dl/g, inclusive, the polyphenylene ether copolymer having, at a molecular terminal, a group represented by formula (1) or formula (2) at an average number of 1.5 to 3 per one molecule, and the metal foil has a first surface that is in contact with the insulating layer, the first surface having a 10-point average roughness (Rz) of 2.0 μm or less, and includes a barrier layer disposed at a side of the first surface, the barrier layer containing cobalt,

in formula (1), R¹ represents a hydrogen atom or an alkyl group having 1 to 10 carbon atoms, and R² represents an alkylene group having 1 to 10 carbon atoms,

in formula (2), R³ represents a hydrogen atom or an alkyl group having 1 to 10 carbon atoms.
 7. The metal foil with resin according to claim 6, wherein the polyphenylene ether copolymer includes 2,6-dimethylphenol and a bifunctional phenol.
 8. The metal foil with resin according to claim 6, wherein the group represented by formula (1) is at least one selected from the group consisting of a p-ethenylbenzyl group and an m-ethenylbenzyl group. 